Overview Grinding Applications

Transcription

1 GRINDING 14E

2 Overview Grinding Applications SRG Workpieces High precision grinding Steady Rests Grinding diameter Ø mm Camshafts Crankshafts Shafts Chapter 1 Fine adjustment of the grinding center Retractable arms Suitable for follow down grinding High rigidity AcuGrind Workpieces High precision air chucks Chuck sizes Ø mm Bearing rings Bearing parts Bolts Camshafts Shafts Chapter 2 For OD and ID clamping Built-in pneumatic actuation For universal grinding applications Typ D Diaphragm chucks Chuck sizes Ø mm Diaphragm technology for highes precision External or pitchline clamping With or without open center Workpieces Gears Gear shafts Chapter 3 FDG High precision face drivers for machining between center pins Workpieces Camshafts Gear shafts Shafts Machining of the entire surface of the workpiece with one single operation Power operated on the side of the spindle Highest rund-out accuracy Chapter 4 CPG Pneumatic pancake cylinder for diaphragm chuck D-VARIO and face driver FDG Easy installation for grinding and turning machines without hydraulic unit Operating pressure 2-8 bar Medieum feed for air / coolant Chapter 5 EMS Workpieces Segment sleeve mandrels Clamping diameter Ø mm Bearing rings Bearing parts For ID clamping Rigid design Chapter 6

3 SRG Chapter 1 SRG High precision grinding Steady Rests Grinding diameter Ø mm Fine adjustment of the grinding center Retractable arms Suitable for follow down grinding High rigidity

4 New grinding Steady Rest with fine adjustment of the center SRG Grinding Steady Rest Application/customer benefits Support of shaft type workpieces on grinding machines Particularly suitable for the machining of crankshafts and camshafts Rapid set up of the Steady Rest to the grinding diameter due to the fine adjustment Suitable for Follow down grinding Scope of delivery Basic Grinding Steady Rest SRG Delivery in transport box (Padholder for the middle piece, Clamping Kit and Pad Kits are not scope of delivery. See therefor the overview for the configurations below.) NEW 1 2 Technical Features Horizontal fine adjustment of the grinding center 2. Vertical fine adjustment of the grinding center 3. Retractable Steady Rest arms 4. Port for compressed air against dust and coolant 5. Monitoring of end positions with standard proximity switches (switches not included) Overview Configuration Select padholder for the middle piece (SRG 1 and 2) Select clamping kit (SRG 2.1 and SRG 4) Select Pad Kit Padholder for the middle piece Consisting of padholder middle piece (incl. mounting material) 3 versions available: 0 degree, ± 5 degree, ± 7 degree Can be rotated by 180 degrees SMW-AUTOBLOK Type Basic Steady Rest Clamping range Padholder 0 degree Padholder ± 5 degree Padholder ± 7 degree Clamping kit Clamping range Clamping kit 0 degree Clamping kit ± 5 degree Clamping kit ± 7 degree Pad Kit Standard Pad Kit Special*** Id.No. mm Id.No. Id.No. Id.No. mm Id.No. Id.No. Id.No. Id.No. Id.No. SRG SRG SRG SRG * * * * Clamping Kit for the arms Consisting of 2 nests for the arms and 1 padholder for the middle piece (incl. mounting material) The different clamping ranges can be covered by different clamping kits * * I II III I II III IV ** ** ** ** ** ** ** ** ** ** ** ** ** ** ** Pad Kit Consisting of 3 pads incl. 3 mounting screws Standard for clamping range as shown on the Steady Rest Special for shifting of the clamping range -5 mm Working pressure bar Follow down grinding Yes Yes Yes Yes * Consisting of padholder for the middle piece incl. mounting material ** Consisting of padholder for the middle piece and the nests for the arms incl. mounting material *** Clamping range -5 mm

5 P2 P2 P1 P1 S1 A A R R C1 C1 E2 E2 U1 U1 U2 U2 U3 U3 E E F2 F2 I I SRG 1 Grinding Steady Rest Dimensions and technical data Monitoring of position Ø 12 mm G1/8" Port for compressed air Cylinder port G 1/4" close Cylinder port G 1/4" open E1 E1 E3 E3 S2 S2 S1 F1 F1 O1 O1 Drain O2 O2 V V D5 D5 D4 D4 D3 D3 D2 D2 D1 D1 C C J J Y Y X X H H Lift thread M8 Vertical fine adjustment K K G G Horizontal fine adjustment Subjected to technical changes For more detailed information please ask our customer service G 1/8" Port centralized lubrication SMW-AUTOBLOK Type Id. No. Minimum clamping diameter Maximum clamping diameter Clear for part loading Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure Working pressure Repeatability accuracy Mass SRG U1 mm 20 U2 mm 35 U3 mm 70 mm mm ± 0.20 mm mm ± 0.10 A mm C mm 55.9 C1 mm 67.5 D1 mm 22.8 D2 mm 22.7 D3 mm 22.7 D4 mm 22.7 D5 mm 22.6 E mm E1 mm 76.2 E2 mm 85.7 E3 mm 20.7 F1 mm 95.2 F2 mm 63.5 G mm 39 H mm 5 I mm 13 J mm K mm 16 O1 mm 4.5 O2 mm P1 mm 41 P2 mm 35 R mm 82.8 S1 mm 11 S2 mm 13.5 T mm 39 V mm 37 X mm 19.5 Y mm 19.5 mm 69.9 cm² 6.38 max bar 45 bar mm kg 8.7

6 A R C1 E2 P2 P1 U1 U2 U3 E1 E F2 I SRG 2 Dimensions and technical data Grinding Steady Rest Monitoring of position Ø 12 mm G1/8" Port for compressed air Cylinder port G 1/4" close F1 Cylinder port G 1/4" open O1 Drain O2 S V D4 D3 D2 D1 C J Vertical fine adjustment Horizontal fine adjustment X Y H Lift thread M8 T K G Subjected to technical changes For more detailed information please ask our customer service G 1/8" Port centralized lubrication SMW-AUTOBLOK Type Id. No. Minimum clamping diameter Maximum clamping diameter Clear for part loading Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure Working pressure Repeatability accuracy Mass SRG U1 mm 30 U2 mm 60 U4 mm 80 mm mm ± 0.20 mm mm ± 0.14 A mm C mm 79 C1 mm 88.4 D1 mm 31.8 D2 mm 27.4 D3 mm 27.3 D4 mm 31.7 E mm E1 mm 84.1 E2 mm 23.8 F1 mm 95.2 F2 mm 71 G mm 45 H mm 5 I mm 13 J mm K mm 19 M mm 41 O1 mm 4.5 O2 mm P1 mm 42 P2 mm 35 R mm 94.7 S mm 13.5 T mm 45 V mm 42 X mm 13 Y mm 19 mm 73.4 cm² 7,07 max bar 45 bar mm kg 11.8

7 A A R R C1 C1 E1 E1 P2 P1 P2 P1 U1 U2 U1 U2 U3 U3 E E F2 F2 I I SRG 2.1 Grinding Steady Rest Dimensions and technical data Monitoring of position Ø 12 mm G1/8" Port for compressed air Cylinder port G 1/4" close E2 E2 F1 F1 Cylinder port G 1/4" open O1 O1 Drain O2 O2 Lift thread M8 S S D4 D4 D3 D3 D2 D2 D1 D1 C C J J V V Vertical fine adjustment Horizontal fine adjustment X X Y Y H H T T K K G G Subjected to technical changes For more detailed information please ask our customer service G 1/8" Port centralized lubrication SMW-AUTOBLOK Type Id.No. Minimum clamping diameter Maximum clamping diameter Clear for part loading Horizontal adjustment range Vertical adjustment range Cylinder stroke Piston area Operating pressure Working pressure Repeatability accuracy Mass Modular nests for the arms: (*) mm clamping range by using clamping kit I (**) mm clamping range by using clamping kit II (***) mm clamping range by using clamping kit III SRG U1 mm 12 * 28 ** 44 *** U2 mm 28 * 44 ** 60 *** U3 mm 30 * 46 ** 62 *** mm mm ± 0.20 mm mm ± 0.14 A mm C mm 79 C1 mm 88.4 D1 mm 31.8 D2 mm 27.4 D3 mm 27.3 D4 mm 31.7 E mm E1 mm 84.1 E2 mm 23.8 F1 mm 95.2 F2 mm 71 G mm 45 H mm 5 I mm 13 J mm K mm 19 M mm 41 O1 mm 4.5 O2 mm P1 mm 42 P2 mm 35 R mm 94.7 S mm 13.5 T mm 45 V mm 42 X mm 13 Y mm 19 mm 66.4 cm² 7,07 bar 45 bar mm kg 11.2

8 I SRG 4 Dimensions and technical data Grinding Steady Rest A Monitoring of position for switches Ø 12 mm J U3 H G1/8 Port for compressed air E E1 P2 P1 S U1 U2 F1 F2 U3 **** *** ** * O1 O2 D2 D1 C V Drain Cylinder port G 1/4 close Cylinder port G 1/4 open Lift thread M10 Vertical fine adjustment Horizontal fine adjustment T G K G 1/8 Port centralized lubrication Subjected to technical changes For more detailed information please ask our customer service SMW-AUTOBLOK Type Id. No. SRG Minimum clamping diameter U1 mm 43 * 49 ** 61 *** 73 **** Maximum clamping diameter U2 mm 55 * 61 ** 73 *** 85 **** Clear for part loading U3 mm 220 Horizontal adjustment range mm mm ± 0.20 Vertical adjustment range mm mm ± 0.14 A mm C mm D1 mm D2 mm 28.3 E mm E1 mm F1 mm 108 F2 mm 108 G mm 55 H mm 5 I mm 13 J mm K mm 18 O1 mm 4.5 O2 mm P1 mm 48 P2 mm 43 S mm M12 (6x) T mm 54.5 V mm 106 mm Cylinder stroke Piston area Operating pressure max Working pressure Repeatability accuracy Mass Modular nests for the arms: (*) mm clamping range by using clamping kit I (**) mm clamping range by using clamping kit II (***) mm clamping range by using clamping kit III (****) mm clamping range by using clamping kit IV cm² bar 30 bar 7-25 mm kg 20

9 AcuGrind Chapter 2 AcuGrind High precision air chucks Chuck sizes Ø mm For OD and ID clamping Built-in pneumatic actuation, no hydraulic cylinder required For universal grinding applications

10 High precision air chuck Ø mm with built-in pneumatic actuating cylinder fully sealed AcuGrind Application/customers benefits Sealed standard chuck for high-precision turning and grinding Highest accuracy - runout and repeatability Built-in pneumatic actuation, no hydraulic cylinder required Technical features Base jaws case hardened Repeatability < mm proofline chucks = fully sealed - low maintenance Standard equipment Odering example Power chuck AcuGrind 150, Id.No Boring ring for I.D. clamping Boring ring for O.D. clamping Lubricating oil Tapped holes in the face are optional. β Master jaw AcuGrind 80 E F I H J K Master jaw AcuGrind α A C D N M K J N M L J M M L M M Master jaw AcuGrind 125 K J N M L Connection AcuGrind D E Master jaw AcuGrind 150 Master jaw AcuGrind 250 M M K N M L N M M K J M M H 6,6 G T Subject to technical changes. For more detailed information please ask for customer drawing. L Technical data SMW-AUTOBLOK Type AcuGrind 80 AcuGrind 100 AcuGrind 125 AcuGrind 150 AcuGrind 200 AcuGrind 250 Order number Id.No Outside Ø A Centering Ø h7 C Distributor Ø D min. / max. E 9.5 / / / / 18-3 / / Height F Chuck mounting bolts G 6 x M5 6 x M5 6 x M6 6 x M6 6 x M10 6 x M10 H I Pin Ø J Jaw mounting bolts K M5 M5 M5 M5 3/8" - 24 UNF 3/8" - 24 UNF Distance to 1. pin max. / min. L / / / / / / M N Bolt circle Ø T α β Repeatability mm < < < < < < Radial jaw stroke mm Speed max. min Clamping force at 6 bar kn Operating pressure bar Weight kg jaw and 4-jaw power chucks available on request.

11 AcuGrind Top jaws for AcuGrind power chucks Top jaws for AcuGrind WAK Soft top jaws SBK Segment jaws 120º Chuck type Material Id.No. Height Id.No. Height AcuGrind 80 Aluminium Steel Aluminium AcuGrind Steel Aluminium AcuGrind Steel Aluminium AcuGrind Steel Aluminium AcuGrind Steel AcuGrind 250 Aluminium Steel Top jaws in special version on request. 4

12 Air feed tubes fix AcuGrind Air feed tubes fix (AP) SMW-AUTOBLOK Speed Type max. (min -1 ) AP2S AP3S AP2S/AP3S = with serration Version 2 airways 3 airways AP2S AP3S S = 5 mm C D LS E G Chuck type LS E C D S F G Spindle length Chuck adaptor Bushing (included in scope of delivery of the air feed tubes type AP) Adaptor (mounting ring manufactured by the customer) Safety distance AcuGrind chuck Support ring for tube bundle longer 600mm Ordering example NOTE In case of an order of the air feed tubes type AP, the length of the air feed tube is necessary. For calculating the correct length of the air feed tube (LR) are the following dimensions necessary: LS, E, C, D and the chuck type! NOTE Use only with clean and oiled air.

13 AcuGrind Air feed tubes flex Air feed tubes flex (APFL) SMW-AUTOBLOK Speed Type Id.No. max. (min -1 ) APFL APFL Version 2 airways 3 airways APFL2 APFL3 Rotary joint APFL Aluminium bushing Air feed tube adaptor Spindle Adaptor plate Power chuck AcuGrind PH 6-2 / PH 6-3 SMW-AUTOBLOK Type PH 6-2 PH 6-3 Id.No Number of airways 2 3 Airways outside Ø (mm) 6 6 Airways inside Ø (mm) 4 4 Medium air air Max. operating pressure (MPa) at 20 C Operating temperature -20 C C -20 C C Length (mm) Max. working distance (mm) Outside Ø coil (mm) Material Polyurethan Polyurethan Colour black black 6

14 Type D Chapter 3 Typ D Diaphragm chuck Chuck sizes Ø mm Diaphragm technology for highest precision Pitch line clamping or O.D. clamping With or without open center

15 Type D Diaphragm chuck QUICK JAW CHANGE SYSTEMS Main dimensions and technical data N C1 K C H M Stroke S F1 F2 A Ø E Ø F Ø P G1 Q R Ø D Ø D1 G Subject to technical changes For more detailed information please ask for customer drawing J B SMW-AUTOBLOK Type Mounting Clamping range min./max. Jaw height Piston stroke Jaw stroke at distance H Draw pull min./max.* Draw pull for chuck open Moment of inertia Weight without top tooling D-210 D-260 D-315 Size A5 A6 A6 A8 A8 A mm B mm C mm C1 mm D mm D1 mm E mm F mm G M10 M12 M12 M16 M16 G1 M26 x 1.5 M26 x 1.5 M30 x 1.5 H mm J mm K mm M mm N mm P H6 mm Q mm R mm S mm F1 kn F2 kn kg m kg Recommended actuating cylinders Type SIN-DFR SIN-DFR SIN-DFR *Additional actuation force to the diaphragm spring clamping force applied by the clamping cylinder. Advice: The max. allowed speed for the application is permanently marked on the corresponding top jaws and must not be exceeded. Advice: Please note, that it is important, that the cylinder force for pushing and pulling can be set to different values independently! Important: Never rotate the chuck without inserted jaws, otherwise the centrifugal force compensation mechanism will get damaged.

16 Type D Diaphragm chuck QUICK JAW CHANGE SYSTEMS Clamping jaws Closed center rotating cylinder Installation Jaws type AJaws type BJaws type C External clamping Pitchline clamping with roller cage Pitchline clamping with clamping pin Actuating cylinder SIN-DFR for diaphragm chuck Type D D-KOMBI Radial-axial clamping QUICK JAW CHANGE SYSTEMS Clamping jaws Rotating double piston cylinder Installation Jaws type AJaws type BJaws type C External clamping Pitchline clamping with roller cage Pitchline clamping with pin Actuating cylinder ZHVD-DFR for D-KOMBI Technical features Special double piston cylinder to actuate D-KOMBI 2 independent pistons for diaphragm jaws and axial swing clamp drive Rotating unions for 1 or 2 media 2 Linear Position Systems LPS for monitoring of the piston strokes Standard equipment Cylinder with kit for LPS, without LPS position sensor rotary union 2 media rotary union 1 medium

17 D-KOMBI Main dimensions and technical data Radial-axial clamping QUICK JAW CHANGE SYSTEMS N K M C C1 H Ø A Ø E V Ø D1 FD FC U T Stroke S FB FA Ø D G2 Ø D2 S1 ø F G G1 J B Subject to technical changes For more detailed information please ask for customer drawing SMW-AUTOBLOK Type Mounting Clamping range without fingers Clamping range with fingers Jaw height Piston stroke Axial stroke swing clamps Jaw stroke at distance H Draw pull min./max.* Draw pull for chuck open Draw pull swing clamps max. Draw pull swing clamps open Moment of inertia Weight without top tooling Size D-210 KOMBI D-260 KOMBI D-315 KOMBI D-400 KOMBI A5 A6 A6 A8 A8 A8 A11 A mm B mm C mm C1 mm D mm D1 mm D2 mm E mm F mm G M10 M12 M12 M16 M16 M16 M20 G1 M28 x 1.5 M28 x 1.5 M28 x 1.5 M28 x 1.5 G2 M14 x 1.0 M14 x 1.0 M14 x 1.0 M14 x 1.0 H mm J mm K mm M mm N mm S mm S1 mm T mm U mm V mm mm FD kn FC kn FB kn FA kn kg m kg Recommended actuating cylinder Type ZHVD-DFR ZHVD-DFR ZHVD-DFR ZHVD-DFR * Additional draw pull to the diaphragme force actuated by the actuating cylinder Advice: The max. allowed speed for the application is permanently marked on the corresponding top jaws and must not be exceeded. Important: Never rotate the chuck without inserted jaws, otherwise the centrifugal force compensation mechanism will get damaged.

18 Type D-PLUS Diaphragm chuck QUICK JAW CHANGE SYSTEMS Open center diaphragm chuck Main dimensions and technical data jaws and clamping ranges see chuck type D C G S A E F D G1 T D1 Subject to technical changes For more detailed information please ask for customer drawing J B SMW-AUTOBLOK Type D-PLUS-260 D-PLUS-315 Mounting Size A mm B mm C mm D1 mm E mm F mm G M16 M16 G1 M42x1.5 M60x1.5 J mm 6 6 P H6 mm Piston stroke S mm Through hole T mm Draw pull min./max.* F1 kn Draw pull for chuck open F2 kn Moment of inertia kg m Weight without top tooling kg Recommended actuating cylinders Type SIN-DFR SIN-DFR *Additional actuation force to the diaphragm spring clamping force applied by the clamping cylinder. Advice: The max. allowed speed for the application is permanently marked on the corresponding top jaws and must not be exceeded. Advice: Please note, that it is important, that the cylinder force for pushing and pulling can be set to different values independently! Important: Never rotate the chuck without inserted jaws, otherwise the centrifugal force compensation mechanism will get damaged.

19 Radial O.D. or pitch line clamping with central bore Centrifugal force compensation Type D-PLUS Diaphragm chuck QUICK JAW CHANGE SYSTEMS Jaws type AJaws type BJaws type C External clamping Pitchline clamping with roller cage Pitchline clamping with clamping pin Actuating cylinder SIN-DFR for diaphragm chuck Type D-PLUS Technical features Special cylinder to actuate the diaphragm chuck Large/small piston area for opening/ clamping Rotary unions for 1 or 2 media Linear positioning system LPS to monitor the piston stroke Standard equipment Cylinder with kit for LPS-XS installation without LPS-XS position sensor LPS-XS see page 237 B G3/8" A G3/8" min.111 G3/8" max ø max.37 min.17 ø8 M24 ø25 ø38 ø40 ø80 ø120 ø145 SIN-DFR-LPS-XS for rotary union 1 medium Id. No (without rotary union*) SIN-DFR-LPS-XS with rotary union 2 media Id. No (rotary union 2 media included) Piston surface Pressure Pull Push Speed Leakage Weight Moment Weight of Weight of A B A B min./max. min./max. max. at 30 bar 50 C cylinder of rotary union rotary union pull push min/max (36 bar max.) inertia 1 medium 2 media cm 2 cm 2 bar bar kn kn r.p.m. dm 3 /min kg kg m 2 kg kg / * To be ordered seperately!

20 Type D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Main dimensions and technical data Application/customer benefits Flexible solution for grinding with quick adjustment for short set up times Technical features Adjustable, modular jaw system for clamping different work pieces with the same jaws Key Lock System for quick positioning of the pitch of different work pieces Micrometer fine adjustment of the center line For small, medium and large batch sizes Workstop with medium feed for air sensing and integrated coolant nozzles optional Jaws for O.D. clamping (Type A) optional D-Vario Configurator: free application to configurate your set up ( Standard equipment Diaphragm chuck D-Vario (with mounting bolts) Optional accessories in the modular system: Pitch line clamping 6 different jaw sets for different outside diameters Key Lock System for different pitches of gears (see figure A, B and C) Clamping pins for different modules (Dia. of ball Ø 3,0 mm to 6,0 mm) Locators O.D. clamping (Type A) 4 different jaw blanks for different outside diameters Factory finished jaws Locators With these free of charge D-VARIO Configurator you will be able to create individual configurations for different gears and set-ups. For input the data, there are only 3 steps needed. Optional you could also make the interpretation of the work stop and the associated support bolts. Through the integrated export function, the results can be saved at any time or transfered to a printer. Start Web-App: Safe and quick configuration of all set-ups for different gears Web-APP: from anywhere with any device feasible (internet access needed) Availability for exporting all resolution of the results A: Number of teeth is divisible by 3 Example of application: gear with number of teeth [z] = 30 B: Number of teeth is not divisible by 3 Example of application: gear with number of teeth [z] = 31 C: Number of teeth is not divisible by 3 Example of application: gear with number of teeth [z] = , , ,75 123, , , Specification of Key Lock System: 3x Key straight Specification of Key Lock System: 1x Key straight, 2x Key for number of teeth 31 Specification of Key Lock System: 1x Key straight, 2x Key for number of teeth 32

21 Type D-VARIO Main dimensions and technical data Diaphragm chuck FLEXIBLE MODULAR SYSTEM Top jaws and locator base are optional. Subject to technical changes For more detailed information please ask for customer drawing. SMW-AUTOBLOK Type Mounting Id. No. Locating Face for Locator Clamping range min./max. Swing min. Swing max. Jaw height Piston stroke Jaw stroke at distance H Draw pull min./max.* Draw pull for chuck open Moment of inertia Weight without top tooling D-VARIO 215 Z A mm 215 B mm 49.5 C mm 68.5 D mm D1 mm 215 D2 mm 264 E mm 170 F mm G G1 M12 M24x1.5 H mm 40.5 J mm 6 P H8 mm 25 Q mm 7 R mm 20 S mm 1.0 mm 0.95 kn 0-15 kn 15 kg m kg 12.2 Recommended actuating cylinders Type SIN-DFR * Additional draw pull to the diaphragme force actuated by the actuating cylinder Advice: Please note: It is important, that the cylinder force for pushing and pulling can be set to different values independently!

22 Type D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Overview clamping kit Configuration of the set up for pitch line clamping within only 5 steps: I II III IV V First you have to choose your matching top jaw (size 1-6) for the outside diameter [d a ] of the gear to be machined. Each size of top jaw can cover 20 mm outside diameter using two different types of clamping pins (Type A and B). One set of top jaw consists of 3 pieces including 1 straight Key Lock insert. The determination of the spherical clamping pins is made according to the ball dimension of the gear. There are 2 types of clamping pins: Type A for the first 10 mm of the clamping range of the top jaws. Type B for the second 10 mm of the clamping range of the top jaws. Optionally prelocator pins are available. Prelocator pins are used at automatic loading. The determination is made according to the clamping pins used. One set of Key Lock insert consists of 2 keys. Gears, which number of teeth that is divisible by 3 can be machined with 3 of the same type Key Lock insert (straight). For all gears, which number of teeth is not divisible by 3, there are different key insert sets available according to the number of teeth. The Key Lock inserts are the same for all 6 sizes of top jaws. The following types of locator bases are available: Type A: without air sensing / without nozzle for coolant Type B: without air sensing/with nozzle for coolant Type C: with air sensing / with nozzle for coolant The height of the locator posts is depending on the gear. Overview of the clamping kit: Top jaws (1 set = 3 pcs.) available in 6 sizes for different outside diameters [d a ] 1 pcs. key insert straight contained in the set of the top jaws Gear Parameter for the configuration of the clamping kit: Outside diameter [d a ] Clamping pin (1 set = 3 pcs.) Ball diameter 3-6mm for different ball dimensions Gear Gear Key Lock inserts (1 set = 2 pcs.) for different numer of teeth [z] Number of teeth [z] Ball dimension D-Vario Configurator free application to configurate your set up

23 Configuration of the clamping kit I. Determination of the top jaws Top Jaws Size Type D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Outside diameter of gear d a mm Number of teeth z number Inside clearance diameter of jaws mm Swing diameter mm Weight / set kg Order number / set of 3 pieces Id. No Clamping pin Type Clamping range A B A B A B A B A B A B mm II. / III. Determination of the clamping pins (and optional prelocator pins) Clamping pin type Set Type A Available prelocator pins Ball diameter Ø 3,0 Ball diameter Ø 3,5 Ball diameter Ø 4,0 Ball diameter Ø 4,5 Ball diameter Ø 5,0 Ball diameter Ø 5,5 Ball diameter Ø 6,0 Id. No. Id. No. Id. No. Id. No. Id. No. Id. No. Id. No. Type B Available prelocator pins Clamping pins Clamping pin type A [ Top jaw 1 Top jaw 2 Top jaw 3 Top jaw 4 Ø mm Ø mm Ø mm Ø mm Clamping pin type A For the first 10 mm of the clamping range of the top jaws. Ball diameter Ø 3; 3,5; 4; 4,5; 5; 5,5; 6 Clamping pin type B Top jaw 5 Top jaw 6 Top jaw 1 Ø mm Ø mm Ø mm Clamping pin type B For the second 10 mm of the clamping range of the top jaws. Ball diameter Ø 3; 3,5; 4; 4,5; 5; 5,5; 6 [ Top jaw 2 Top jaw 3 Top jaw 4 Top jaw 5 Top jaw 6 Ø mm Ø mm Ø mm Ø mm Ø mm Compatibility All types and sizes of clamping bolts are compatible to all top jaws.

24 Type D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Configuration of the clamping kit IV. Key Lock inserts for different number of teeth of gears Id. No. Key Lock insert for gears which number of teeths is not divisible by 3 (1 set = 2 pcs.) z = 10 z = 11 z = 13 z = 14 z = 16 z = 17 z = 19 z = 20 z = 22 z = z = 25 z = 26 z = 28 z = 29 z = 31 z = 32 z = 34 z = 35 z = 37 z = z = 40 z = 41 z = 43 z = 44 z = 46 z = 47 z = 49 z = 50 z = 52 z = z = 55 z = 56 z = 58 z = 59 z = 61 z = 62 z = 64 z = 65 z = 67 z = z = 70 z = 71 z = 73 z = 74 z = 76 z = 77 z = 79 z = 80 z = 82 z = z = 85 z = Id. No. Key Lock insert for gears which number of teeths is divisible by 3 (1 set = 2 pcs.) straight Order Example: Gear with number of teeth 32 not divisible by 3 Id. No (1 set = 2 pcs.) Gear with number of teeth 33 divisible by 3 Id. No (1 set = 2 pcs.) 1 straight Key Look that comes with the chuck always remains in use. Key Lock insert (1 set = 2 pcs.) [ Top jaw 1 Top jaw 2 Top jaw 3 Top jaw 4 Compatibility All Key Lock inserts are compatible to all top jaws. Top jaw 5 Top jaw 6

25 Type D-VARIO Configuration of the clamping kit V. Locator base Diaphragm chuck FLEXIBLE MODULAR SYSTEM Locator base Clamping pin Top jaw Workpiece Locator post Ø 10mm Locator base Determination of height of locator posts: = Distance between clamping position and locating face Height of locator posts [H] = 32,5 mm - Clamping position = 1/2 serration length / at longer serrations it is the requested clamping position. In case the lowest face is not the locating face, please ask our customer service. Locator base Type A Type B Type C Medium feed for air sensing - - X Noozle for coolant - X X Locating diameter min. D min Locating diameter max. D1 max Width B mm Order Number Id. No Locator posts with contact face diameter [E] 2,5 mm Height[H] = 12,5 mm Height[H] = 15,0 mm Height[H] = 17,5 mm Height[H] = 20,0 mm Height[H] = 22,5 mm Height[H] = 25,0 mm Height[H] = 27,5 mm Height[H] = 30,0 mm Height[H] = 32,5 mm Height[H] = 35,0 mm Height[H] = 37,5 mm Height[H] = 40,0 mm Height[H] = 42,5 mm Height[H] = 45,0 mm Height[H] = 47,5 mm Height[H] = 50,0 mm I.D. Number is for one set (=3 pieces) Locator posts with contact face diameter [E] 4,5 mm Height[H] = 12,5 mm Height[H] = 15,0 mm Height[H] = 17,5 mm Height[H] = 20,0 mm Height[H] = 22,5 mm Height[H] = 25,0 mm Height[H] = 27,5 mm Height[H] = 30,0 mm Height[H] = 32,5 mm Height[H] = 35,0 mm Height[H] = 37,5 mm Height[H] = 40,0 mm Height[H] = 42,5 mm Height[H] = 45,0 mm Height[H] = 47,5 mm Height[H] = 50,0 mm I.D. Number is for one set (=3 pieces)

26 Type D-VARIO Diaphragm chuck FLEXIBLE MODULAR SYSTEM Jaws Type A Jaws type A for O.D. clamping Jaws Type A (through hardened) D max. Clamping diameter range D min. Jaws type A Clamping Range Ø D min. - D max. Weight / set Blank jaws (set of 3 pcs.) Jaws factory finished* (set of 3 pcs.) mm kg 1,1 1,1 1,0 1,0 1,0 0,8 Id. No Id. No * Jaws are factory finished according to the specified clamping diameter. Note: The clamping diameter must be specified in case of order. Device Grinding rings (1 Set = 2 pcs.) Device for machining of the blank jaws type A Recommended grinding rings Jaws type A sizes Jaws type A sizes The device is needed to pre-machine the blank jaws type A. Then, the jaws must be finish ground to the clamping diameter on the D-Vario chuck. For this operation, the jaws have to be clamped with the grinding rings. Grinding data 1. Grinding A1 D = 177,0 mm residual jaw stroke 0,25 mm 2. Grinding A2 D = 176,9 mm residual jaw stroke 0,20 mm 3. Grinding A3 D = 176,8 mm residual jaw stroke 0,15 mm 4. Grinding A4 D = 176,7 mm residual jaw stroke 0,10 mm The clamping diameter A1 is used for the first finish grinding process. The smaller clamping diameter of the grinding rings (A2-A4) are used to regrind worn or damaged existing jaws.

27 FDG Chapter 4 FDG High precision face drivers for machining between center pins Machining of the entire surface of the workpiece with one single operation Power operated on the side of the spindle Highest rund-out accuracy

28 Face drivers for grinding between center pins Power operated on the side of the spindle FDG Application/customer benefits Machining of the entire surface of the workpiece in one single operation For the machining of the surface of soft and hardened workpieces Center pin with carbide insert for highest running accuracy Technische features Highest run-out accuracy < mm Compensating drive elements Retractable drive pins in case of on- or off-loading Fine adjustment at face drivers for highest run-out requirements Standard equipment Accessories Face driver FDG Pneumatic pancake cylinder CPG-FDG without changeable parts Id.No A Cylindrical retainer Z140 on flange adapter total stroke 6 Ø165 Ø Ø160 Ø133,4 3x for x M12 Ø106,375 (KK Gr.6) d5 Ø6 d8 D1 D2 D3 d7 d9 d Short taper retainer DIN size 6 directly onto machine spindle A 92 Subject to technical changes. For more detailed information please ask for customer drawing. Technical Data Id.-No. Id.-No. Type d Center d5 d7 d8 d9 Clamping dia Ø Z140 KK size 6 Ø D1 D2 D FDG , FDG FDG , , FDG , , FDG , FDG , FDG , Face drivers with morse taper retainer according to DIN 228 available on request. NOTE Pancake cylinder CPG for the pneumatic actuation of face drivers FDG available.

29 d8 d1 60 d1 d7 60 I I I FDG Face drivers for grinding between center pins Changeable parts Center heads / Center pins Application/customer benefits Center pin with carbide insert Maximum rigidity Highest change accuracy Fixed safely via set screw and plane surface inside the face driver Center heads Type FDG 0 and FDG 1 60 center with carbide coating. Center pins Type FDG 2 to FDG 6 carbide design. A 28 Center heads Type FDG 0 / FDG 1 Center pins Type FDG 2 - FDG 6 Ø6 A d8 d4 d9 Id.-No. Type d1 d4 Center d7 d8 d9 Center pin Ø FDG FDG FDG FDG FDG FDG FDG Further dimensions on request. Drive pins with diamond coating Model A Ø6 Ø6 Ø6 Model B Model C Drive pins diamond Id.-No. Type Clamping I Model drive pin diameter diamond D1 1.5 C diamond D2 3 B diamond D3 3 A Further dimensions on request. Drive pins for torque transmission onto the workpiece Drive pins with diamond coating High frictional coefficient Clamping diameter D1/D2/D3 see page 1.

30 CPG Chapter 5 CPG Pneumatic pancake cylinder for diaphragm chuck D-VARIO and face driver FDG Easy installation for grinding and turning machines without hydraulic unit Operating pressure 2-8 bar Medieum feed for air / coolant

31 A С D E G F K B P J Pneumatic pancake cylinder D-VARIO / FDG Pneumatic actuation (2-8 bar) Easy installation for grinding and turning machines Application/customer benefits For the actuation of diaphragm chuck D-VARIO and face driver FDG Easy installation for grinding and turning machines without hydraulic unit Compact design Technical features Operating pressure 2-8 bar Maximum axial piston force push 21 kn and pull 7 kn 1 medium feed for air / coolant Air service unit with water separator and oil feed necessary Air feed tube necessary Standard equipment Odering example Pneumatic pancake cylinder Version D-VARIO Id.No (without air feed tube) Version FDG Id.No APFL3 Id.No CPG H M W N Accessory Q S O R APFL3 Air feed tube 3 Connections: 1x Actuation "push" 1x Actuation "pull" 1x Additional medium channel for air/coolant U Subject to technical changes. For more detailed information please ask for customer drawing. A Id. No Technical Data SMW-AUTOBLOK Type Piston stroke Axial force 6 bar (pull) Axial force at 6 bar (push) Moment of inertia Max. speed Piston area (piston pull) Piston area (piston push) Operating pressure Weight CPG 215 A mm 215 B mm 170 C mm 195 D mm E mm 30 F mm M25x1.5 G mm 16 H mm 54.5 J mm 116 K mm L mm 2 M mm 46.3 N mm 6.2 O mm 3 P mm 3x M12x120 Q mm M6 R mm M14 S mm 16 U mm 4 kn 5 kn 16 kg m² 0.09 U/min cm² 291 cm² 98 bar 2-8 kg 11.1

32 EMS Chapter 6 EMS Segment sleeve mandrels Clamping diameter Ø mm For ID clamping Rigid design

33 I EM-S Segment sleeve mandrel Ø mm Segment sleeve mandrel power operated Technical design Size 1-4 Large expansibility 1. Basic body EM-S with spindle adapter 2. Segment sleeve mandrel (vulcanized + case hardened) with bayonet quick change. Clamping sleeves in size EM-S-1 with three segments, clamping sleeves from size EM-S-2 on with six segments for better gripping force distribution. 3. Workstop Overview clamping ranges EM-S-4 Clamping range mm EM-S-3 Clamping range mm EM-S-2 Clamping range mm EM-S-1 Clamping range mm Clamping sleeves EM-S-1* Ø 18 Id. No Ø 31 Id. No EM-S-2** Ø 30 Id. No Ø 43 Id. No EM-S-3** Ø Id. No Ø 58 Id. No Ø 71 Id. No EM-S-4** Type EM-S-1 EM-S-2 EM-S-3 EM-S-4 Id. No A C D E F H I K M N O M5 M5 M5 M EM-S Ø Id. No Ø Id. No Ø Id. No * The clamping sleeves have a max. radial expansibility in diameter of ± 0.4 mm from the nominal diameter. ** The clamping sleeves have a max. radial expansibility in diameter of ± 0.6 mm from the nominal diameter. Soft work stop blank EM-S-2 / EM-S-3 / EM-S A D N O H F C E M K

34 Segment sleeve mandrel Ø mm Size 1-4 Large expansibility EM-S Segment sleeve mandrel power operated Application/ customer benefit Ideal for volume production and hard turning / grinding with wear resistant, case hardened and vulcanised clamping sleeves Highest accuracy and high torque transmission by means of fixed mandrel body Axial pull down by the axial clamping movement of the clamping sleeve = best face run out Clamping sleeve quick change for short setup times Preparation for air sensing Technical details Large expansibilty mm depending on the size (The clamping sleeves have a max. radial expansibility in diameter of ± 0.4 mm or ± 0.6 mm from the nominal diameter.) Power operated Rigid design with flange mounting Tapped holes in the face for axial stops Standard equipment Bayonet quick change Base mandrel with mounting bolts L4 L6 L9 L3 L2 L1 air sensing S2 S3 K D7 S1 D3 D2 D1 A2 D6 A1 D5 D4 L5 L7 L8 L5 Attention: Sleeve mandrel in open position = right end position! Gap "L8" must remain open when using airsensing! Subject to technical changes. For more detailed information please ask for customer drawing. L6 L4 L3 L9 L2 L1 SMW-AUTOBLOK Type EM-S-1 EM-S-2 EM-S-3 EM-S-4 Mounting A5 A6 Z140 A5 A6 Z140 A5 A6 A08 Z140 Z170 A5 A6 A8 Z140 Z170 Id. No Short taper mounting DIN A1 A5 A6 - A5 A6 - A5 A6 A8 - - A5 A6 A8 - - Center mounting A2 H D D D D4 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 M30x1.5 D5 H D D7 4 x M10 4 x M12 4 x M10 4 x M10 4 x M12 4 x M10 4 x M10 4 x M12 4 x M16 4 x M10 4 x M12 4 x M10 4 x M12 4 x M16 4 x M10 4 x M12 L L L L L L L Gap L L Technical data Clamping range S max. clamping length S min. clamping length S Axial stroke K Expansibilty in dia max. actuating force kn max. speed min max. transmittable torque Nm rec. actuating cylinders SIN-S 70 SIN-S 85 SIN-S 85 SIN-S 85